CN110692182B

CN110692182B - Winding template, winding device and method for operating a winding device

Info

Publication number: CN110692182B
Application number: CN201880036373.0A
Authority: CN
Inventors: S·萨迪库
Original assignee: Elmotec Statomat Vertriebs GmbH
Current assignee: Schaeffler Elmotec Statomat GmbH
Priority date: 2017-04-27
Filing date: 2018-04-23
Publication date: 2022-09-16
Anticipated expiration: 2038-04-23
Also published as: US20200091801A1; US11843290B2; CN110692182A; DE102017109100A1; WO2018197422A1; EP3616309B1; PL3616309T3; EP3616309A1

Abstract

The invention relates to a winding template (1) for winding a conductor (100) into a coil winding (101), in particular for subsequently being pulled into a stator carrier, having a template front part (2) and a template rear part (3), wherein the template front part (2) and the template rear part (3) define a helically linear winding path (P) for the conductor (100) about a helical axis (W) with a circumferential surface (4), and wherein support elements (10, 11) are arranged along the winding path (P), which protrude beyond the circumferential surface (4) and laterally define the helically linear winding path (P). The invention further relates to a winding device (50) having such a winding stencil (1) and to a method for operating the winding device (50).

Description

Winding template, winding device and method for operating a winding device

Technical Field

The invention relates to a winding stencil, a winding device having such a winding stencil and a method for operating such a winding device.

Background

Winding devices for producing coil windings and for equipping a pulling-in tool for pulling the coil windings into a stator in groups are known from the prior art. The coil winding is produced by winding a wire (typically an enameled copper wire) in a spiral around a winding former and is subsequently placed in a drawing tool. For this purpose, the wire is guided from the wire store to the winding forme by means of a wire feed. A distinction is made between the so-called Flyer method, in which the wire-conveying device is guided around the former, and the winding method, in which the winding former is rotated.

It is also known to guide a plurality of wires side by side to a winding former and thus to apply a plurality of parallel-running conductor windings simultaneously to the former.

The pull-in tool has a ring consisting of a plurality of pull-in webs distributed uniformly over the circumference. When the coil windings of the current phases are placed around these pull-in lamellae, the free ends of these pull-in lamellae are guided through the front opening of the stator carrier to the rear opening of the stator carrier. By means of the pull-in star which is moved with the projections through the intermediate spaces between these pull-in lamellae, the coil windings are pulled through the stator carrier and fall out of the pull-in tool in an ordered winding sequence into the pull-in slots between the stator teeth of the stator carrier. Said per se known process is not discussed in detail here, since it is not directly the subject of the present invention. It was ascertained, however, that the pull-in procedure can be carried out relatively quickly, while the winding of the individual coil windings takes more time overall. Furthermore, it is crucial that the individual turns of the coil winding are correctly placed in the drawing tool in order to achieve a high fill factor of the drawing groove and to avoid efficiency losses of the motor due to eddy currents in the drawing groove. The amount of electrical conductor which is introduced into the available winding space, in particular pulled into the slot, including its insulation layer, is referred to as the mechanical fill factor. This means that it is to be avoided that the turns of the wire exceed adjacent turns when winding and stripping the coil winding. However, this is often not achieved in the prior art. In the past, the efficiency of large electric motors has often not been fully exploited due to grid operation. In mobile applications with accumulators, the efficiency is of particular significance, in particular in the field of electric vehicles.

Another disadvantage of the prior art is that the winding form is of very large length in order to be able to place the necessary number of turns for the pull-in slots of a larger stator completely on the form. This results in a large and inert design of the die plates, so that these are positionally accurate and dimensionally stable during the winding process. This makes the machine large and expensive to purchase and results in a large installation area. The problem is particularly pronounced when winding and guiding a plurality of tensioned individual wires in a bundle in parallel, since this leads to a significant increase in traction and is accompanied by a risk of damage to the wire to be wound or to the device.

Disclosure of Invention

The object of the present invention is therefore to overcome the disadvantages of the prior art and to find a solution with which a coil winding for subsequent pulling-in into a stator can be produced cost-effectively, which also provides the following preconditions: it is possible to provide a stator having a high fill factor of the pull-in slot and a high efficiency of the electric motor. For this purpose, high production speeds of the coil winding should be assisted as far as possible in the case of compact machine dimensions. The solution should also be easy to operate and reliable in operation.

The invention relates to a winding former for winding a wire into a coil winding, having a former front and a former rear, wherein the former front and the former rear define a helical winding path for the wire around a helical axis with one circumference. Along the winding path, a plurality of support elements are provided which project beyond the circumferential surface and laterally, in particular locally, define the helical winding path.

The support element according to the invention has the advantage that individual turns of the coil winding can be prevented from changing order during the stripping. Another advantage is that the support element allows applying a multilayer winding to the winding form. The necessary length of the winding template can thereby be substantially reduced by a factor corresponding to the number of layers, i.e. in the case of two layers only half as long winding templates are required for winding coil windings having the same wire length. The entire machine can thus be designed more compactly, since the lever force exerted by the tensioned wires on the formwork is smaller. The wires should all have the same diameter. This makes the machine cost-effective and requires a small installation area. The winding template is used in particular for preparing the coil winding to be pulled into the stator frame or into a pull-in groove of the stator frame.

According to a particular embodiment, the support element is arranged such that the helical winding path has a uniform width. This supports, in particular, the holding together of the wires adjacently situated between the supporting elements. Whereby for example the wires of the second layer on the first layer do not push the wires underneath apart. Preferably, the support element is elongate and oriented between transverse to the helical axis to parallel to the winding path. Thereby, the turns of the winding path can be put together closely. It is also helpful for the width of the support element transverse to the winding path to be preferably at most 3 times the diameter of the wire to be wound, more preferably at most 2 times the diameter of the wire to be wound and particularly preferably at most 1.5 times the diameter of the wire to be wound.

In one embodiment, the support element projects beyond the circumferential surface at least by 1.5 times, preferably at most by 3 times, the diameter of the wire to be wound. From about 1.5 times the diameter of the wire, the second layer of wires may be laterally supported. A preferred upper limit (i.e., 3 times the wire diameter) enables lateral support of the third layer of wire. Up to this height, the support element can also be designed to be relatively narrow, so that the spacing between two adjacent turns of the winding path is kept small. Furthermore, up to this upper limit, the coil windings can also be stripped from the winding former by suitable measures and placed in a pulling tool.

In a particular embodiment of the winding stencil, it is provided that the winding stencil has a wire feed for the plurality of wires, with which a first part of the plurality of wires can be placed parallel to one another in a first layer on the winding path and a second part of the plurality of wires can be placed parallel to one another in a second layer on the first layer. It is advantageous here if a plurality of wires are wound onto the winding template, wherein the sum of the wire lengths per revolution of the winding template is high compared to the length requirement along the winding template. The layers are preferably applied to the template simultaneously. Preferably, the plurality of wires is at most 40, further preferably at most 35 and particularly preferably at most 30. Furthermore, the plurality of wires is preferably at least 4, more preferably at least 5, still more preferably at least 6, and particularly preferably at least 8.

In a special embodiment, the wire feed device comprises individual wire guides for a plurality of wires, wherein the individual wire guides for a first part of the plurality of wires are arranged along a first row and the individual wire guides for a second part of the plurality of wires are arranged along a second row. Thus, the wire has been sorted into two layers before being placed on the winding form. For this purpose, the first and second rows should be arranged parallel and adjacent to each other.

In practical applications it has proven particularly practical that the second part of the plurality of wires is the remaining part of the plurality of wires. Thus, all the wires are distributed on the first and second layers.

Alternatively, however, an embodiment of the tool template is also possible in which the winding template has a wire feed for a plurality of wires, with which it is possible to simultaneously place first portions of the plurality of wires parallel to one another in a first layer on the winding path, place second portions of the plurality of wires parallel to one another in a second layer on the first layer and place the remaining portions of the plurality of wires parallel to one another in a third layer on the second layer. Thus, more windings can be placed on the winding form per form length. In principle, even more than three layers of wires can be provided. However, a maximum of five layers of embodiment is sufficient on the basis of an upper limit of a maximum of 40 wires.

The support element according to the invention prevents the wires of the first layer from slipping off. Additionally, the support element should prevent the wires of the second layer from falling onto the circumferential surface or between the wires of the first layer. The same applies to embodiments provided with more than two layers.

A design in which the uniform width of the helically wound path is greater than the sum of the wire diameters of the first layer is advantageous. Thus, the wires of the first layer fit between the support elements without being crushed and/or damaged. It is also preferred that the uniform width of the helically shaped winding path is less than the sum of the wire diameter of the first layer plus the diameter of the other (non-existing) wire. Thus, no additional wires are fitted between the support elements, so that the wires of the second layer do not fall onto the circumferential surface or get jammed between the wires of the first layer.

In order to be able to layer as many wires as possible between the support elements, an arrangement is proposed according to which the number of wires in the first layer corresponds to the number of wires in the second layer and, if other layers are present, to the number of wires in the other layers.

In a special embodiment of the winding stencil, it is furthermore provided that the support element comprises a first support element which can be lowered, preferably completely, into the circumferential surface. This makes it easy to peel the coil winding off the winding form.

In this case, a design is preferred in which a plurality of or all of the first support elements have a common drive. The support element can thus be lowered automatically and the cost of the common drive is low.

A structurally simple embodiment makes it possible to arrange several or all of the first support elements on a common carrier element, wherein the carrier element comprises the first support elements which can be lowered relative to the circumferential surface. Preferably, the carrier element is an elongated carrier strip. Such a carrier strip may be oriented parallel to the winding axis. This can be realized in a structurally simple and cost-effective manner. Furthermore, such a carrier strip can be supported in a lowerable manner in a groove in the front or rear of the formwork. This can also be implemented in a structurally simple manner. I.e. the groove may be designed to be open towards the circumferential surface. Preferably, the first support element is arranged along the carrier strip. In addition, it is preferred that the carrier strip forms part of the circumferential surface or forms a section of the winding path in the undedescended position, i.e. in particular during winding.

A design option is available in which the common drive means is a sliding element which is mounted so as to be movable along a sliding axis, wherein the sliding axis is oriented transversely to the direction of movement of the first lowerable support element and is kinematically coupled to the first lowerable support element. The drive motors can be arranged outside the front and rear formwork sections of the winding formwork by means of the sliding elements. For example, a cam gear or a control cam is suitable for the kinematic coupling.

In a further embodiment, it is provided that the support element has a second support element which cannot be lowered into the circumferential surface. The support element is particularly simple and cost-effective to produce. Furthermore, the support element is particularly operationally reliable.

According to a particular embodiment of the winding template, the helical winding path has a first direction of extension and a second direction of extension oriented transversely to the first direction of extension, wherein the template front part and the template rear part are supported relative to each other in such a way that a first span of the helical winding path in the first direction of extension can be adjusted by adjusting the position of the template front part and/or the template rear part, and a second span of the helical winding path is formed in the second direction of extension. Thus, the first span may be reduced after winding, which makes it easy to peel off the already wound coil winding. Preferably, the first span of the helically wound path in the first direction of extension may be adjusted by adjusting the position of the front and/or rear formwork part in the first direction of extension.

For automated use, it is preferred that the winding stencil has an adjustment drive, by means of which the position of the front and/or rear stencil is adjusted.

In a further embodiment, it is provided that the first support element is oriented in the direction of the second direction of extension. I.e. the span in the second direction of extension, is preferably not variable, thereby making it difficult to peel off the coil windings by means of the support elements provided there. Since the first support element mounted here may be lowered, the coil winding can easily overcome the first support element. Preferably, the first support element is provided only on the front of the formwork. The freedom of movement of the coil winding is limited during the stripping due to the guidance in the pull-in foil. The production costs for the first support element that can be lowered are therefore only incurred for the front part of the formwork and not for the rear part of the formwork.

One embodiment of the winding stencil provides that at least a part of the second support element is oriented in the direction of the first direction of extension. Due to the preferably changeable span in the first direction of extension, there is no need to lower the second support element. Once the span is reduced, the right form-stable coil winding easily slides on the second support element. A portion of the second support element may also be oriented in the direction of the second direction of extension. Preferably, at least a part of the second support elements, preferably all of the second support elements, are provided on the formwork rear portion. In this case, the non-lowerable second support element can slide over the second support element relatively simply when the span in the first direction of extension is reduced.

When the first span is greater than the second span, a number of optional features are particularly suitable. Thereby, for example, the adjustment of the span in the first direction of extension is facilitated without the formwork front and rear portions becoming unstable. This results, in addition, in an oblong to rectangular coil winding which is threaded on the pull-in tool with one of its short sides.

The second span of the helical winding path is preferably invariable. This keeps the complexity and subdivision of the winding form small and its rigidity high.

In a special embodiment, the front and rear formwork sections are arranged on the formwork base. Although designs are also possible in which the front and rear formwork sections are directly connected to one another. However, a more stable support thereof is mostly achieved with a formwork base. In this case, the front formwork part and/or the rear formwork part can be fixedly connected to the formwork base or can be formed integrally therewith. This is particularly stable. Preferably, however, at least one of the parts consisting of the group of the front part of the formwork and the rear part of the formwork is movably supported on the formwork base. Thereby, the template shape can be changed by movement, preferably shortened in extension. A design is particularly preferred, according to which the front and/or rear formwork part is supported on the formwork base so as to be longitudinally displaceable. In this way, it is possible to design the adjustment of the winding stencil to be uniform over the entire length.

A coupling mechanism for connection to a rotary drive may be provided on the template base, wherein the coupling mechanism defines an axis of rotation for the winding template. The winding stencil can thus be connected to the rotary drive. Preferably, the coupling mechanism is disposed on the back side of the template base. The template front and rear are preferably disposed on the front side of the template base.

Furthermore, the winding stencil should have a wire fixing portion in the region of the start of the winding path. The end of one or more wires may be fixed in the wire fixing portion before winding.

According to a particular embodiment, the helically wound path is divided into winding steps, wherein the circumference of one turn around the winding template decreases stepwise, in particular corresponding to the winding steps, from the start of the helically wound path towards the end of the helically wound path. Thus, coil windings with different circumferences and/or for different sheet positions can be produced in the drawing tool. The windings of each winding stage are then pulled into different pull-in slots of the stator frame.

The invention also relates to a winding device having a winding template as described above and below and a pulling tool, wherein the winding template is mounted on a rotary drive and the pulling tool has a loop of parallel and geodetically vertically oriented pulling webs, wherein the winding template and the pulling tool are mounted so as to be movable relative to one another such that a coil winding wound from a conductor on the winding template can be placed from above around one of the pulling webs or a part of the pulling web (in particular an integer). These advantages correspond to the advantages of such a winding stencil, wherein it is to be emphasized in particular that the sum of the wire lengths per revolution of the winding stencil is designed to be high compared to the length requirement along the winding stencil.

Typically, the pull-in tab is fixed on its lower end and is free-standing on its upper end. Furthermore, it is proposed that the pull-in tool be arranged on the tool table. The latter tool table is preferably mounted rotatably and/or movably with the pull-in tool. Thereby, the pull-in tool can be positioned relative to the winding template. Preferably, the winding stencil is mounted in a suspended manner below the rotary drive. Furthermore, the winding device should have a wire accumulator, in particular a wire accumulator with a wire reserve.

When the coil winding is wound in more than one layer, it is proposed that the distance between the drawn-in foils is slightly greater than the factor formed by the diameter of the wire and the number of layers, i.e. the distance > (diameter of wire) x (number of layers). However, the distance should be less than a factor consisting of the wire diameter and the number of layers plus 1, that is to say the distance < (diameter of wire) × (number of layers + 1). The first wires stacked on top of one another can therefore continue to lie next to one another between the lamellae and can furthermore be pushed into the pull-in groove at the same time, i.e. parallel to one another. This results in a particularly rapid pulling-in of each line and a high fill factor.

The invention further relates to a method for operating a winding device as described above and below for producing a coil winding using a winding former and for providing a pulling tool for subsequently pulling the coil winding into a stator carrier, in which method a conductor is first wound onto the winding former along a helical winding path by rotating the winding former. The turns of the wire extending along the helical winding path are then placed around one of the pull-in webs or a portion of the pull-in web of the pull-in tool. The turns of the wire extending along the helically wound path are then stripped from the winding form over the support element and placed in a pull-in tool. According to the method, the support element prevents the position of the individual turns of the conductor from changing until the stripping. This ultimately leads to a higher achievable fill factor of the pull-in slot and to fewer vortices and a higher efficiency of the stator.

Preferably, the steps of winding, placing and stripping are repeated until at least all coil windings of one phase of the stator of the electric motor are placed in the pull-in tool.

In a special method embodiment, the support element projects beyond the circumference at least by 1.5 times, preferably at most by 3 times, the diameter of the conductor to be wound, wherein the winding template has a wire feed for a plurality of conductors, with which, during winding, first portions of the plurality of conductors can be placed parallel to one another in a first layer on the winding path and second portions of the plurality of conductors can be placed parallel to one another in a second layer on the first layer. This achieves that the ratio of the sum of the wire lengths per revolution of the winding stencil to the length requirement along the winding stencil is high. During the traction force exerted by the tensioned wire and caused by the winding, the winding template is correspondingly short, stable and positionally accurate.

According to another method option, the support element comprises a first support element that can be lowered into the circumferential surface, wherein the first support element is lowered into the circumferential surface after the winding is placed around the pull-in web and before the winding is released from the winding mandrel. This facilitates removal, since the coil winding simply slides over the descending first support element.

In addition or alternatively, it can optionally be provided that the helical winding path has a first direction of extension and a second direction of extension oriented transversely to the first direction of extension, wherein the former front and the former rear are supported relative to one another in such a way that a first span of the helical winding path in the first direction of extension can be adjusted by adjusting the position of the former front and/or the former rear, wherein a second span of the helical winding path is formed in the second direction of extension, and that after the winding has been placed around the pull-in web and before the winding has been stripped off, the position of the former front and/or the former rear is adjusted in such a way that the first span is shortened. Therefore, the coil winding can be easily peeled off.

This attempt may achieve the unexpected result of stator efficiency improvement when the placement pattern of the plurality of parallel wires is rotated 180 degrees (or a multiple of 180 degrees) in the method step, more precisely after every half or full revolution of the winding form. The twist thus produced in the coil winding is then positioned on the stator end when being pulled into the pull-in slot, i.e. outside the pull-in slot. An increase in efficiency can also be achieved without support elements along the winding path. The twisting is particularly effective when the conductor is wound onto the winding template in multiple layers. For this purpose, a plurality of support elements is preferably provided. To achieve twisting, the wire feeding device can be coupled to the turning device in such a way that the wire feeding device can be pivoted back and forth through 180 degrees (or multiples of 180 degrees) together with the turning device. Preferably, this occurs about a (virtual) pivot axis which is located in the center of the plurality of wires guided in parallel.

Furthermore, the method can be carried out with reference to all the above-mentioned and below-mentioned features of the winding template and of the winding device.

The winding device and the method can optionally be supplemented as follows: at least two winding forms according to the invention are positioned side by side and correspond to the same drawing tool. Such a second winding stencil can be supplied with wire by a second wire supply and a second wire transport device for the second wire. Preferably, the rotary drives of the first and second winding forms can be operated simultaneously, preferably synchronously. Preferably, the first and second winding forms are also mounted in an adjustable manner relative to the drawing tool in such a way that the coil windings produced on the first winding form can be placed around one of the sheets or a part of the sheet of the drawing tool at the same time or simultaneously with the coil windings produced on the second winding form. This is preferably done in a diametrically opposed manner. This has the following advantages: at least two coil windings can be produced simultaneously or simultaneously on separate winding templates, which are functionally associated with the device, and these coil windings can then also be placed simultaneously in the pulling-in tool. The entire machine is thus almost no larger than a device with only one winding form, since the base surface for the wire stock is basically only slightly provided during the production planning. The winding forms can be arranged on a common carrier, so that a common feed drive can move both winding forms together with the wound coil winding synchronously relative to the drawing-in tool.

Drawings

Further features, details and advantages of the invention result from the following description of embodiments with the aid of the drawings. Wherein:

FIG. 1 shows a side profile view of a winding form;

fig. 2 shows a schematically illustrated cross section of a winding form;

fig. 3 shows a schematically illustrated longitudinal section of the winding form;

fig. 4 shows a winding device with two winding forms and a pull-in tool; and

fig. 5 shows a part of a cross section of the pull-in foil and the pull-in groove.

Detailed Description

A lateral profile view of the winding form 1 can be seen in fig. 1. The winding former 1 is used to wind the wire 100 into a coil winding 101 for the stator, which is then placed in a pulling tool. Fig. 2 shows a schematically illustrated cross section and fig. 3 shows a schematically illustrated longitudinal section of a winding stencil similar to fig. 1. The same reference number (Bz.) denotes a technical feature of the same kind.

As can be seen in fig. 1, the winding stencil 1 has a stencil front part 2 and a stencil rear part 3, which together form a common circumferential surface 4. The latter peripheral surface defines a helical winding path P for the wire 100 about the helical axis W. The winding path P results from the wire 100 being wound onto the circumferential surface 4 afterwards and need not be identified by physical elements on the circumferential surface 4. The only essential condition is that the circumferential surface 4 is adapted to helically position the wire 100. The circumferential surface 4 is oriented substantially parallel to the screw axis W. In the present case, two shoulders of the circumferential surface 4 are visible, wherein the circumference of the upper shoulder around the circumferential surface 4 is greater than the circumference of the lower shoulder. Said shoulder is called the winding stage. Accordingly, the helical winding path P is divided into winding stages in which the circumference of one turn around the winding form 1 is gradually reduced from the start E1 of the helical winding path P toward the end E2 of the helical winding path P. The coil windings 101 of the different winding stages are then placed around the different pull-in webs of the pull-in tool and are then also pulled into the different pull-in slots of the stator carrier.

The helical winding path P has a first direction of extension R1 and a second direction of extension R2 oriented transversely thereto, such that the wound coil winding 101 has a first diameter according to a first span W1 of the helical winding path P in the first direction of extension R1. Furthermore, the rolled-up coil winding 101 has a second diameter oriented transversely thereto, which is realized by a second span W2 (see fig. 2) of the helical winding path P in the second direction of extension R2.

The template front 2 and the template rear 3 are arranged on the front side 8 of the template base 5. The start E1 of the winding path P is located in the region of the formwork base 5 and the end E2 is located at the opposite ends of the formwork front and

rear parts

2, 3. Opposite the front side 8, the template base 5 has a rear side 7, on which a coupling mechanism 6 for connection to a rotary drive is arranged. The coupling mechanism 6 defines the axis of rotation a of the winding stencil 1.

The formwork rear part 3 is mounted on the formwork base 5 so as to be displaceable, in particular longitudinally displaceable. The front part 2 of the formwork is fixedly connected with a formwork base 5. The former front 2 and the former rear 3 are thus supported relative to one another in such a way that the first span W1 of the helical winding path P can be adjusted by adjusting the position of the former rear 3 in the first direction of extension R1. For this purpose, an adjustment drive is preferably provided, with which the position of the template rear part 3 is adjusted. Generally, the first span W1 is greater than the second span (see reference W2 in fig. 2 and 3), which is not changed by adjustment.

Further, the wire fixing portion is provided in the area of the starting end E1 of the winding path P on the template base 5. In which the free ends of one or more wires 100 are fixed before winding.

It can also be seen that the

support elements

10, 11 are arranged along the winding path P. These support elements project beyond the peripheral surface 4 and locally laterally define a helical winding path P. For this purpose, the

support elements

10, 11 are arranged such that the helical winding path P has a uniform width. The supporting

elements

10, 11 project beyond the circumferential surface 4 by more than 1.5 times the diameter of the wire 100 to be wound.

Furthermore, the

support elements

10, 11 are elongate and oriented transversely to the screw axis W. Alternatively, the support elements can also be oriented obliquely, in particular such that they are oriented parallel to the winding path P. The width of the supporting

elements

10, 11 transverse to the winding path P is approximately the diameter of the wire 100 to be wound.

It is possible to simultaneously place first portions of the plurality of wires 100 on the winding path P in the first layer S1 in parallel with each other and second portions (i.e., remaining portions) of the plurality of wires 100 on the first layer S1 in the second layer S2 in parallel with each other by means of a wire feeding device (not shown) for the plurality of wires 100. In the present case, eight wires 100 are wound simultaneously into two four layers S1, S2. All wires 100 have the same diameter and are enameled copper wires provided by a single wire store with wire stock.

In order to be able to place the wires 100 in an orderly manner on the winding path P, the wire conveying device should have a wire guide for the wires 100, in particular a single wire guide in which one wire is individually guided or a plurality of wire guides in which at least two wires are guided adjacently and in contact. The wire guides for the first portion of the plurality of wires 100 should be arranged in a first row and the wire guides for the second portion of the plurality of wires 100 should be arranged in a second row. Thus, the rows are preferably adjacent and parallel to each other.

The

support elements

10, 11 prevent the wire 100 of the first layer S1 from slipping off. Furthermore, the support element prevents the wires 100 of the second layer S2 from falling onto the circumferential surface 4, in particular by holding the first layer S1 together.

It can be seen that the uniform width of the spiral-shaped winding path P is slightly wider than the sum of the diameters of the wires 100 of the first layer S1 (see, in particular, fig. 3). But no other conductors 100 are matched between them. In other words, the uniform width of the spiral-shaped winding path P is smaller than the sum of the diameter of the wire 100 of the first layer S1 plus the diameter of another (non-existing) wire. Preferably, the number of the conductive lines 100 in the first layer S1 corresponds to the number of the conductive lines 100 in the second layer S2.

In order to allow the coil windings 101 to simply slide down from the winding former, a part of the

support elements

10, 11 is formed by a first support element 10 which is characterized in that it can be lowered into the circumferential surface 4. A plurality of the first support elements 10 share a common drive mechanism 12 (see fig. 2 for this purpose), which is designed as a sliding element. The sliding element is mounted so as to be movable along a sliding axis oriented parallel to the winding axis W. The sliding axis is therefore oriented transversely to the direction of movement of the driven first bearing element 10. The sliding element is coupled kinematically to the first support element 10 that can be lowered by means of a control cam or cam gear. It can be seen that all first supporting elements 10 are oriented in the direction of the second direction of extension R2 and are arranged on the formwork front part 2. Furthermore, a plurality of support elements 10 are located on a common carrier strip which is oriented parallel to the winding axis W and is supported in a lowerable manner in a groove in the front formwork section 2. The first support element 10 is arranged along the carrier strip. The grooves are open toward the circumferential surface 4. In the non-lowered position, i.e. during winding of the conductor, the region between the carrier strip and the first support element 10 together forms a part of the circumferential surface 4 and thus also a section of the winding path.

However, not all

support elements

10, 11 can be lowered, but a second support element 11 is also provided, which cannot be lowered into the circumferential surface 4. Said second supporting elements are all arranged on the formwork rear part 3. The second support element 11 points in the direction of the first and second direction of extension R1, R2.

Fig. 4 shows a winding device 50 with two winding forms 1 and a pull-in tool 60. The invention also relates specifically to embodiments with only one winding form 1. The two winding forms 1 correspond in their technical characteristics to the winding forms of fig. 1, 2 and 3, respectively. The two winding forms 1 are however configured in mirror image with respect to one another and run in opposite directions. In principle, three or four winding formers can also be provided.

Each winding form 1 is supported in a suspended manner below the rotary drive 51. A tool table 62 is placed below the winding form 1, and a drawing tool 60 is provided on the tool table. A tool table 62 having a pull-in tool 60 is rotatably and movably supported. The pull-in tool 60 has a circular ring of parallel and geodetically vertically oriented pull-in lamellae 61. The number of pull-in tabs corresponds to the number of pull-in slots of the stator frame to be equipped later. Furthermore, the pull-in tab 61 is fixed at its lower end and is separate at its upper end.

The winding template 1 and the pulling tool 60 are now mounted so as to be displaceable relative to one another, so that the coil windings 101 wound on the winding template 1 by the wire 100 can each be placed from above around one or a part of the pulling foil 61. This is preferably done in a diametrically opposed manner. Here, the coil winding 101 is located mostly outside the pull-in tool 60 and is placed on the tool table 62.

With such a winding device 50, a method for producing a coil winding 101 with a winding template 1 and for equipping a pull-in tool 60 for subsequently pulling the coil winding 101 into a stator carrier 70 (see reference numeral 70 in fig. 5) can be carried out, in which method the following steps are carried out:

a) winding the wire 100 onto the winding form 1 along the helical winding path P by rotating the winding form 1;

b) the turns of the wire 100 extending along the helical winding path P are then placed around one of the pull-in webs 61 or a portion of the pull-in tool 60;

c) the turns of the wire 100 extending along the helically shaped winding path P are then stripped from the winding form 1 over the

support elements

10, 11 and placed in the pulling tool 60.

These steps should be repeated until all coil windings 101 of one phase of the stator of the electric motor are placed in the pull-in tool 60.

Preferably, when wound on each winding form 1, the first portions of the plurality of wires 100 are simultaneously placed in the first layer S1 on the winding path P in parallel with each other and the second portions of the plurality of wires 100 are placed in the second layer S2 on the first layer S1 in parallel with each other, respectively.

The first support element 10 is preferably lowered into the circumferential surface 4 after the winding has been placed around the pull-in foil 61 and before the winding is stripped from the winding form 1.

Additionally, after placing the turns around the pull-in tab 61 and before stripping the turns, the position of the stencil rear portion 3 should be adjusted such that the first span W1 is shortened. This can be done before, after or simultaneously with the lowering of the first support element 10.

Fig. 5 shows a portion of the cross section of the two pull-in lamellae 61 of the pull-in tool 60 and the pull-in groove 72 between the two stator teeth 71 of the stator carrier 70. These pull-in tabs 61 are fitted over the stator teeth 71 in a form-fitting manner, so that they do not change their position during pulling-in. An insulating layer 73 is first introduced into the pull-in groove 72, so that the stator frame 70 is not under stress in the event of an insulation break on the conductor 100. For example, insulating paper may be put into the drawing groove 72 as the insulating layer 73. It can be seen that some of the coil windings 101 have been pulled into the pull-in slots 72. Furthermore, eight further wires 100 are passed through the coil winding 101 between the two pull-in foils 61. The eight wires are located in the first and second layers as during winding, so that two wires 100 side by side are always pulled simultaneously into the pull-in slot. For this reason, the distance between the pull-in foils is slightly larger than the factor formed by the diameter of the wire and the number of layers. Furthermore, the distance is less than a factor of 1 added by the diameter and number of layers of the wire, that is (diameter of wire) × (number of layers) < distance < (diameter of wire) × (number of layers + 1).

The invention therefore also relates to a supplementary or separate method for pulling in a coil winding, in which the coil winding is pulled through a stator frame by means of a pulling tool having a pulling-in lamella and a pulling-in star or a pulling-in mushroom, wherein the distance between the pulling-in lamellae is slightly greater than a factor formed by the diameter of the wire and the number of layers depending on the preceding turn of the coil winding, and wherein the distance is smaller than a factor formed by the diameter of the wire and the number of layers plus 1, and wherein a number of wires depending on the number of layers are simultaneously pulled into the pulling-in groove adjacently.

The invention is not limited to any of the above described embodiments but can be modified in many different ways.

All features and advantages which are derived from the claims, the description and the drawings, including structural details, spatial arrangements and method steps, are essential to the invention both by themselves and in various combinations.

List of reference numerals

1 winding form

2 front part of the shuttering

3 rear part of the formwork

4 peripheral surface

5 template base

6 coupling mechanism

7 back side

8 front side

10 first support element

11 second support element

12 (of the supporting element) drive mechanism

50 take-up device

51 rotation driving device

60 pull-in tool

61 pull-in sheet

62 tool table

70 stator support

71 stator tooth

72 draw-in groove

73 electrically insulating layer

100 wire

101 coil winding

Axis of rotation A

D (of wire) diameter

Start of E1 (winding route)

End of E2 (winding path)

P-helical winding path

R1 first direction of extension

R2 second direction of extension

S1 first layer

S2 second layer

W helical axis

W1 first span

W2 first span

Claims

1. Winding form (1) for winding a wire (100) into a coil winding (101), having a form front (2) and a form rear (3), wherein the form front (2) and the form rear (3) define with a circumferential surface (4) a helically shaped winding path (P) around a helical axis (W) for the wire (100),

characterized in that the pattern of the plurality of parallel wires (100) is rotated by 180 degrees or a multiple of 180 degrees after each half or complete rotation of the winding stencil (1), wherein the winding stencil (1) has a wire feed for the plurality of wires (100), which wire feed is coupled to the turning device in such a way that it can be pivoted back and forth by 180 degrees or a multiple of 180 degrees together with the wire feed.

2. The winding form (1) according to claim 1, characterized in that the wire (100) is wound on the winding form (1) in a plurality of layers.

3. Winding form (1) according to claim 1 or 2, characterized in that the wire conveyor is coupled with the turning device in such a way that the turning device can be pivoted back and forth together with the wire conveyor about a pivot axis which is located in the center of the plurality of parallel wires (100).

4. Winding template (1) according to claim 1 or 2, characterized in that support elements (10, 11) are provided along the winding path (P), which project beyond the circumferential surface (4) and laterally define a helically shaped winding path (P).

5. Winding template (1) according to claim 4, characterized in that the support elements (10, 11) are arranged such that the helically shaped winding path (P) has a uniform width.

6. Winding form (1) according to claim 4, characterized in that the supporting elements (10, 11) protrude beyond the circumferential surface (4) at least by 1.5 times the diameter (D) of the wire (100) to be wound.

7. Winding form (1) according to claim 6, characterized in that the supporting elements (10, 11) protrude beyond the circumferential surface (4) by a maximum of 3 times the diameter (D) of the wire (100) to be wound.

8. Winding stencil (1) according to claim 4, characterized in that with the wire feeding device it is possible to simultaneously place a first part of the plurality of wires (100) parallel to each other in a first layer (S1) on the winding path (P) and a second part of the plurality of wires (100) parallel to each other in a second layer (S2) on the first layer (S1).

9. Winding form (1) according to claim 4, characterized in that the helically wound path (P) has a first direction of extension (R1) and a second direction of extension (R2) oriented transversely thereto, wherein the form front (2) and the form rear (3) are supported relative to each other in such a way that a first span (W1) of the helically wound path (P) in the first direction of extension (R1) can be adjusted by adjusting the position of the form front (2) and/or the form rear (3), and in that a second span (W2) of the helically wound path (P) is formed in the second direction of extension (R2).

10. Winding device (50) having a winding template (1) according to one of claims 1 to 9, which is mounted on a rotary drive (51), and having a pull-in tool (60) with a loop of parallel and geodetically vertically oriented pull-in webs (61), wherein the winding template (1) and the pull-in tool (60) are mounted so as to be movable relative to one another in such a way that a coil winding (101) wound from a conductor wire (100) on the winding template (1) can be placed from above around one of the pull-in webs (61) or a part of the pull-in web.

11. Winding device (50) according to claim 10, characterized in that the winding device (50) has a wire conveying device which is coupled with a turnover device in such a way that it can be pivoted back and forth by 180 degrees or a multiple of 180 degrees together with the turnover device.

12. Spooling apparatus (50) as defined in claim 11, wherein the flipping apparatus is capable of pivoting back and forth about a pivot axis that is centered on a plurality of parallel wires.

13. Method for operating a winding device (50) according to one of claims 10 to 12 for producing a coil winding (101) from a winding template (1) and for equipping a pulling-in tool (60) for subsequently pulling in the coil winding (101) into a stator carrier (70), comprising the following steps:

a) winding the wire (100) onto the winding form (1) along a helical winding path (P) by rotating the winding form (1);

b) placing a turn of the wire (100) extending along a helically-shaped winding path (P) around one of the pull-in webs (61) of the pull-in tool (60) or a portion of the pull-in web;

c) the turns of the conductor wire (100) extending along the helically shaped winding path (P) are stripped from the winding template (1) and placed in a pulling tool (60).

14. The method of claim 13, wherein step a) is followed by: the placement pattern of the plurality of parallel wires is rotated 180 degrees or multiples of 180 degrees.

15. Method according to claim 13 or 14, characterized in that support elements (10, 11) are provided along the winding path (P), which support elements project beyond the circumferential surface (4) and laterally define a helically shaped winding path (P), which support elements (10, 11) project beyond the circumferential surface (4) at least by 1.5 times the diameter (D) of the wire (100) to be wound, and in that the winding template (1) has a wire conveying device for a plurality of wires (100), with which, upon winding, simultaneously a first part of the plurality of wires (100) is placed parallel to each other in a first layer (S1) on the winding path (P) and a second part of the plurality of wires (100) is placed parallel to each other in a second layer (S2) on the first layer (S1).

16. Method according to claim 15, characterized in that the support element (10, 11) projects beyond the circumferential surface (4) by a maximum of 3 times the diameter (D) of the wire (100) to be wound.